Electro-thermal co-design of a variable pole toroidal induction motor

The United States Department of Energy targets an 88 % reduction in motor and power electronics volume by the year 2025 while minimizing or eliminating magnet usage. Induction machines are a magnet-free alternative with advantages such as low cost, high reliability, and capability of withstanding high short-term overload. To meet these societal goals, we develop an induction machine that uses an electro-thermal co-designed converter-integrated thermal management approach. The machine utilizes toroidal windings in the stator, and an 18-phase power converter to achieve 40 kW/L power density. An optimized jacket design was developed to enable the effective thermal management of the stator and integrated power electronics. The toroidal winding configuration provides advantages for thermal performance over conventional distributed windings due to an increased winding copper surface area without reducing slot-fill factor, thereby allowing for a higher stator density. The improved thermal performance of the toroidal winding design was verified using three-dimensional conjugate computational fluid dynamic simulations. A reduced-order transient model was then developed to generate torque-speed-temperature plots at various load conditions. The transient thermal analysis was extended to verify safe operation of the motor during a typical drive cycle for the desired application. The thermal design models developed in this work are robust and scalable to other motor sizes providing a framework for co-designing and developing thermal management systems for electric motors.